Novel fabric and process



2 Sheets-Sheet l INVENTORS HANS H. KU H N BY MA NUEL A. THO MA S ATTO R NEY July 21, 1954 H. H. KUHN ETAL NOVEL FABRIC AND PROCESS Filed Mayrsl. 1961 F/G. "l"

July 21, 1964 H. H. KUHN ETAL 3,141,810

NOVEL. FABRIC AND PROCESS Filed May 31, 1961 2 Sheets-Sheet 2 INVENTORS HANS H. KUHN MANUEL A. THOMAS ATTORNEY United States Patent Ofi ice ili@ Patented Juiy 21, 1964 3,141,810 NVEL FABRHC AND PRCESS Hans H. Kuhn and Manuel A. Thomas, both of Spartanburg, S.C., assignors to Deering Miiiiken Research Corporation, Spartanburg, S.C., a corporation of Delaware Fiied May 31, 1961, Ser. No. 113,946 17 Claims. (C1. 161-91) This invention relates to finished fabrics adapted for use as upholstery material, particularly in the automotive industry, and characterized by excellent abrasion resistance, hand, luster and flexibility.

In order to provide an upholstery fabric of adequate abrasion resistance, it has been necessary heretofore to incorporate into the face of these fabrics a fairly high proportion of abrasion resistant yarns, such as those composed of nylon. Fabrics constructed in this manner perform well, but because of their higher cost and limitations in the styles available, many efforts have been made to treat less expensive fabrics to accomplish comparable results. Generally, these efforts have involved coating viscose rayon fabrics with films of a polymeric composition. Unfortunately, while some abrasion resistance has been attained in this manner, the resulting fabric has been characterized by a stiff and boardy hand. In addition, the continuous film coating of material on the fabric has given a dull, unsatisfactory finish, while substantially reducing the tear strength of the fabric. Also, the continuous film coating of material applied in the conventional manner destroys the porosity of the fabric, making it particularly unsatisfactory for automotive upholstery uses.

Other procedures have been developed wherein rayon fabrics are impregnated with polymeric materials, but to date these efforts have not proven entirely satisfactory, especially for automotive uses.

lt is an object of this invention to provide an upholstery fabric characterized by a high degree of abrasion resistance with corresponding excellent exibility, hand and luster.

Another object of this invention is to provide such a fabric characterized by excellent resistance to spotting by solvents and water.

Yet another object of this invention is to provide processes whereby these desirable fabrics may be produced.

These objects are accomplished in accordance with this invention by carefully controlling the location on the fabric of the polymeric composition applied to increase the abrasion resistance of the fabric. Preferably, the polymeric composition is deposited on only those yarns forming the face of the fabric, whereby only the uppermost bers in these yarns are held tightly together by the polymeric composition. The polymeric composition is deposited in such a manner that a substantial proportion, for example, at least about 50% by number, of the yarns forming the face of the fabric are free to move relative to adjacent yarns. In this manner, the porosity and identity of the fabric is maintained and, surprisingly, the abrasion resistance is excellent despite the limited amount of polymeric composition utilized. For example, as little as 2% by weight of the fabric of the polymeric composition is adequate to give substantially enhanced abrasion resistance in the fabric so treated, while amounts in excess of about by weight actually become objectionable for optimum performance.

It is believed that the abrasion resistance is enhanced because the remaining fibers of the face yarns, as well as a substantial proportion of the face yarns of the fabric are free to move relative to adjacent fibers and yarns, thereby being less susceptible to deterioration from abrasive forces. For example, When the fabric of this invention is subjected to abrasive forces, those fibers and yarns not held tightly together by the polymeric composition can adjust to positions where they will not be unduly abraded.

In addition to the enhanced abrasion resistance, the fabrics of this invention are characterized by greatly irnproved luster, flexibility and hand over fabrics coated with a polymeric composition as conventionally practiced, because of the limited amount and location of the polymeric composition utilized.

The location of the polymeric composition on the uppermost fibers of the face yarns of the fabric may be controlled by depositing the polymeric composition in those locations and immediately curing the polymeric composition at a rapid rate, whereby the composition becomes fixed in those locations without migrating into the fabric.

1n some of the procedures of this invention, to be described hereinafter, the polymeric composition impregnates the fabric being treated but because of the specialized drying techniques utilized, the polymeric composition actually migrates to the face yarns and surprisingly binds relatively few of the yarns together.

The polymeric composition is preferably cured at a temperature at which the composition coalesces to hold the fibers of the face yarns tightly together, but at a low enough temperature to avoid undue flowing of the composition into the fabric. The curing temperature, therefore, will generally lie within the range of temperatures at which the polymeric composition is plasticized. For the preferred polymeric compositions suitable for use in accordance with this invention, curing is preferably effected by flash drying the treated fabric at these elevated temperatures, preferably between about and about 200 C., or even higher, up to about 300 C.

In this regard, it is preferred that the uncured fabric does not contact an unyielding surface, such as a guide roll, prior to curing as the pressure will effect migration of the polymeric composition into the fabric, thereby necessitating more specialized drying techniques to obtain even fair results.

The location of the polymeric composition on the face yarns is facilitated in a specialized drying technique, wherein the coated fabric is mounted on a frame and placed on a cool glass plate so that the fabric face is oriented outwardly. This assembly is then introduced into an oven at the desired elevated temperature. When this arrangement is utilized, the polymeric composition migrates only to the face yarns during the flash-drying operation because of the differential temperatures between the face of the fabric, which is exposed to the hot air in the oven, and the back of the fabric, which is cooled to some extent by the glass plate. We believe that for this reason, the migration effect occurs to provide a fabric having the polymeric composition in the desired location.

The flash-drying medium may be any conventional drying apparatus, such as hot air ovens or infrared lamp arrays. Preferably an air circulating means is provided so that hot air is circulated through the fabric during drying. The desired location of the polymeric composition is also facilitated when the hot air is blown from the backing through to the face of the fabric, thereby forcing the polymeric composition towards the face of the fabric.

A fabric characterized by a surface deposition on only the uppermost fibers of the face yarns constitutes the most preferred embodiment of the present invention. In this embodiment nearly all the yarns are free to move relative to adjacent yarns. This invention embodies, however, fabrics wherein a fairly high proportion of the yarns are bound together by the polymeric composition, provided sufficient yarns are free to move in order to provide a porous, abrasion resistant fabric. The hand, luster and iexibility of such fabrics will not be as desirable as the preferred fabrics but there are end uses where these properties are not too critical, for example, as in facings, wall coverings, book covers, linings and the like.

1Furthermore, minimal migration of the polymeric composition into the backing yarns of the fabric is also permissible provided the backing yarns remain free to move relative to adjacent fibers and yarns. The fibers in the backing yarns, furthermore, should be no more than loosely held together, if at all, by the polymeric composition, for optimum hand and flexibility. The amount of polymeric material present in the backing, that is, an amount sufficient to hold the fibers of the backing yarns loosely, is usually sufficient to provide the desired protection against unraveling as well as the desired slightly irnproved abrasion resistance and firmness in the backing. If desired, however, the conventional practice of applying a backing layer to the fabric, whether of another fabric or a polymeric composition, may be followed, although this procedure is not required for optimum results.

While the polymeric composition may be added in accordance with this invention to a fabric of any desired construction, particularly desirable results are provided when a fabric composed of continuous filament and spun yarns is utilized. This fabric is most preferably woven so that the face is composed almost entirely of continuous filament yarns. In a particularly preferred fabric, as shown in the drawings, both the face and backing are composed essentially of continuous filament yarns, a spun component being woven between the continuous filament components. In this preferred embodiment of the invention, at least the uppermost filaments of the continuous lament yarns forming the face of the fabric are held tightly together by a coating of the polymeric composition, the remaining filaments of these face yarns being free to move relative to adjacent filaments. It is important that a substantial number of these face yarns are free to move relative to adjacent yarns. Due to the presence of the spun yarn component between the continuous filament components, this particular fabric is characterized by a high degree of flexibility. This flexibility, of course, may be impaired if the polymeric composition is permitted to impregnato the spun yarn component. Good results are obtained, however, even if some of the polymeric composition enters the spun yarn component and essentially all the continuous filaments of the face yarns are held together by the polymeric composition, provided a substantial number of the face yarns remain free to move relative to adjacent yarns.

In the preferred embodiment of this invention, however, only the uppermost filaments of the face yarns are held together by the polymeric composition and essentially all the face and backing yarns are free to move relative to adjacent yarns.

The polymeric composition may be applied to other fabrics, such as fabrics woven from mixed filament and spun yarns, such as wherein both warp and filling yarns are composed of mixed continuous filament and spun yarns, or wherein the face is composed of filament yarns while the backing is composed of spun yarns, or wherein the face is composed of spun yarns and the backing is composed primarily of filament yarns, or wherein the fabric is composed wholly of spun yarns. Spun yarn fabrics, however, tend to absorb a great deal more of the polymeric composition and in some cases more stringent control conditions are required to limit the location of the polymeric composition of the uppermost fibers of the face yarns and to maintain the identity of the face yarns as desired.

From the standpoint of economy, the preferred continuous filament component comprises viscose rayon yarns, although fabrics composed of other synthetic or natural yarns may similarly be improved in accordance with this invention. Suitable fabrics include those containingr multifilament or spun yarns composed of polyamides, such as polyhexamethylene adiparnide or caprolactam; polyesters, such as polyethylene terephthalate;

polyacrylics, such as polyacrylonitrile or copolymers containing at least about by weight combined acrylonitrile, such as acrylonitrile/methyl acrylate copolymers (85/ 15 polyolefins, such as polyethylene and polypropylene; vinyl polymers, such as polyvinyl chloride and polyvinylidene chloride and the like. Cellulosic fibers, including cellulose esters and ethers such as cellulose acetates and ethylcelluose; cotton, flax, jute, hemp, Ramie, paper and the like, are also suitable. Keratin fiber yarns such as wool, alpaca, vicuna, mohair, cashmere, guanaco, camels hair, silk, llama and the like are similarly useful.

Selection of the polymeric composition will, to a great extent, determine the quality of the characteristics imparted to the fabric. Generally, it is preferred to utilize a polymeric composition which will hold the fibers of the yarns tightly together. In addition, the polymeric composition should have a fairly high heat distortion temperature and a fairly low dynamic friction factor.

The extent to which the fibers of the yarns are held together by the polymeric composition can be measured on an Instron tester by selecting a face yarn (e.g., a 200 denier 20 filament viscose rayon yarn) from a treated fabric, partially separating the yarn into two lengthwise sections, clamping one section in each of the two jaws of the Instron tester, laterally separating the jaws 1%. inches and measuring the force required to effect the separation of the yarn portions. This force will be referred to hereinafter as the cohesive force since the cohesion of the polymeric composition between the filaments of the yarns is less than the adhesion of the composition to the filaments. A cohesive force in excess of about 7 grams is preferred for optimum results.

A convenient method of measuring the heat distortion temperature of the polymeric compositions suitable for use in accordance with this invention involves casting a film of any desired thickness, e.g., 0.0039 inch, cutting 1% inch wide strips from the lm, mounting the strip vertically between two clamps so that the clamps contact the strip edges, and attaching a 152 gram weight to the bottom clamp. This assembly is then hung in an oven and the temperature in the oven is increased gradually until the film is distorted to the point that it can no longer support the Weight. The temperature at the point at which the weight is dropped will be referred to hereinafter as the heat distortion temperature. Since abrasive forces usually generate moderately high temperatures, the polymeric composition selected should have a heat distortion temperature of at least about C. This quality of the material must be balanced with the cohesive force of the material, in that compositions having fairly high heat distortion temperature values, eg., greater than about 200, often do not have sufficient cohesive forces to hold tightly together the filaments of the yarns.

The dynamic friction of the polymeric compositions suitable for use in accordance with this invention may be defined as the force in grams necessary to sustain movement of a 192 gram load over a horizontally situated film of the composition. This same measurement may be made for a fabric treated with the polymeric composition. The dynamic friction of the film is preferably below about 55 grams, while the value for the fabric is preferably below about 50 grams.

The above properties are most readily obtained in the use of acrylic polymers, particularly blends of acrylic acid with lower alkyl acrylates, such as methyl and ethyl acrylate. A particularly desirable polymeric composition is an acrylic polymer sold under the trade name of Rhoplex HA12. In the above tests, this material has a cohesive force of 10.89 grams, a heat distortion temperature of C., and a dynamic friction value of 49.4 in the film and 38.6 on Abbeville Mills Corp. fabric Style Number 40613-1, having 0.1582 lbs/yd. of 2 ply, 200 denier 34 filament nylon yarn and 0.3234 lb./yd. of 13 cotton count doubles spun viscose yarns in the filling and 200 denier, `20 filament bright viscose rayon yarn in the warp.

Additional polyemirc compositions include vinyl polymers and their copolymers such as polyvinyl chloride, polyvinylidene chloride, polyvinyl ethers, polyvinyl esters such as polyvinylacetate and its modifications; compounds based on acrylonitrile, such as Hycar rubber and the like, butadiene-styrene copolymers and their modifications as well as addition and condensation polymers such as polyurethanes, epoxy resins, polyesters, polyamides, polycarbonates yand combinations thereof.

The abrasion resistance may be improved slightly by adding to the polymeric composition small amounts (e.g., at least about 0.5% by weight) of a thermosetting resin, such as the phenolics and amino-plasts, including the reaction products of phenol, cresol, xylenol, urea, melamine and -the like with aldehydes, such as formaldehyde. furfuraldehyde and the like. Any amount of resin may be added to the polymeric composition as desired, provided the cohesion of the composition between the filaments of the face fabrics is not unduly affected.

Great care must be taken in applying the polymeric composition to the fabrics to insure that the material will be deposited properly on the face yarns. Total immersion of the fabric for extended periods of time, for example, invariably causes substantially complete impregnation of the fabric and the desirable characteristics of the fabric of this invention are not generally obtained. Spray techniques have been used with sucess but process conditions must be very carefully controlled. It is difiicult, for example, to prevent the polymeric composition from flowing between the face yarns and into the fabric when this procedure is utilized. Clogging of the spray valves is not too uncommon, either, thereby resulting in uneven distribution of the polymeric composition on the fabric. By utilizing a polymeric composition medium of fairly low solids content, e.g., from about 1 to about 3% by weight solids, and by spraying the material onto a rapidly moving fabric, e.g., rabout -30 yds. per minute, the desired location of the polymeric composition may be obtained. The sprayed fabric is taken immediately from the spray chamber into an oven, heated to a temperature approximating the softening point of the polymeric composition to fix the polymeric composition in the desired location and to assist in preventing the migration of the polymeric composition into the fabric. greatly facilitated by running the fabric in a vertical manner and spraying the polymeric composition onto the vertically moving fabric from horizontally displaced spray guns.

The difficulties in controlling the spraying techniques are obviated, however, in a preferred method of applying the material, wherein it is applied to the fabric by means of a trough apparatus including an open-ended trough lined with a porous material, preferably of nylon, in such a manner that the porous material extends through the open end of the trough to form a bag-like protuberance. The lining ma-terial is of such ya weave that the polymeric composition will not flow through except upon Contact with the fabric to be treated. The pressure on the material caused by the running fabric is sufficient to release a limited amount of the polymeric composition evenly onto the fabric surface which contacts the bag. The fabric is then passed immediately into a curing zone and the polymeric composition is rapidly cured before undue impregnaiton of the fabric can occur. Y

Generally, it is preferred to apply the polymeric composition as an aqueous medium, such as an aqueous solution or emulsion. Improved drying is realized in some instances by dissolving or emulsifying the polymeric composition in `an organic medium, such as the lower alkyl alcohols, methanol, ethanol and the like. In this regard, the medium utilized may be foamed, as by agitating vigorously in a Waring Blendor. Prelocation of the polymeric composition on the face yarns is more easily attained when applied in this form, although at a slightly increased cost.

The spraying procedure may be n FIGURE l shows a continuous filament viscose rayon warp-viscose rayon spun filling fabric treated in yaccordance with this invention.

FIGURE 2 illustrates a cross-sectional view of FIG- URE 1 taken along line II--IL FIGURE 3 illustrates the trough-application apparatus for producing the fabrics of this invention.

FIGURE 4 illustrates a cross-sectional View of FIG- URE 3 taken along line IV-IV.

In FIGURE l, there is shown a continuous viscose rayon warp-viscose rayon spun filling fabric woven in such a manner that the continuous rayon yarns 1 compose the face of the fabric, while the spun viscose filling 2 is maintained substantially beneath the continuous filament facing. In this fabric, the face yarns 1 are in a valley in the fabric, while the face yarns, constitute a peakf These latter yarns, therefore, take up more of the polymeric composition than do the valley yarns 1. The integrity of the individual yarns is maintained so that the yarns are free to move relative to adjacent yarns, except for slight adhesion at point 4. Even these yarns which are point bonded along their length to adjacent yarns, however, are still relatively free to move along their length relative to the adjacent yarns. The polymeric composition 5 is seen to have permeated and held together the uppermost filaments of the yarns 1.

FIGURE 2 illustrates the cross section taken along lines II-II of FIGURE l. In this view, the polymeric composition 5 isV seen to have permeated and coalesced around the uppermost filaments of the rayon yarn, leaving the lowermost filaments free to move relative to the other filaments of the yarn. The continuous rayon filaments 6 of the yarns in the backing of the fabric are not affected by the polymeric composition and are free to move relative to one another. Similarly, the yarns of the backing are wholly free to move relative to adjacent arns.

FIGURES 3 and 4 illustrate the trough-application apparatus for producing the fabrics of this invention. In this apparatus, trough 7 is lined with fabric 8 in such a manner ythat a bag-like protuberance 9 is formed. Sponge 10 partially closes off the outlet end of trough 7 in order tot control the flow of polymer from the trough to the baglike protuberance 9. The fabric is folded and attached to the trough around the entire inner surface of the trough to provide closed ends in bag-like protuberance 9.

In operation, the trough is filled to about one-half capacity with a polymeric composition 11, whereupon the bag-like protuberance fills to a level of about l inch. No liquid leaks through the bag until a fabric is passed beneath the trough in rubbing contact with the bag. At this time only, the polymeric composition passes through the fabric onto the filaments forming the face of the fabric.

In the following examples, which illustrate specific embodiments of this invention, the Stoll and Taber tests referred to are conducted in accordance with ASTM tests designated the Inflated Diaphragm Method D1l75-55T -and Rotary Platform, Double Head Method D1l75-55T,

respectively.

Example I Vbly is placed in a tray at approximately a 20 degree angle to the base so that the face of the fabric is exposed. A 4% aqueous emulsion of an acrylic polymeric composition sold under the trade name of Rhoplex HA-12 by Rohm & Haas Co. is poured quickly and evenly over the fabric. The fabric is then permitted to drain, face down with the frame at about an 80 degree angle, for one minute. The frame is reversed 180 so that the frame is still at an angle of about 80 degrees with the fabric face down and the fabric is drained for an additional minute. After weighing (the fabric has increased in weight by 150%, corresponding to about 6% solids on the fabric), the assembly is placed in an oven at 160 C. for 15 minutes, removed and cooled.

Abrasion resistance tests are conducted on the treated fabric and a nylon fabric of the same general construction with 200 denier 20 filament bright nylon yarn Type 180 in the warp and 13/2 spun bright viscose in the filling for comparison. After 300 cycles on the Taber Ill-38 Wheel with a 500 gram load, only a few broken ends are noticed in a microscopic examination of each fabric, while neither fabric is unduly abraded. Similar results are obtained after 1000 cycles on the Taber CS1() wheel with a 250 gram load and after 1600 cycles with a one pound load on the Stoll flat abrasion test.

Examination of the treated fabric under the microscope reveals that the polymeric composition coats only the face yarns of the fabric, leaving them entirely free to move relative to adjacent yarns, except for some slight amount of point bonding at a few locations on the face. The filaments of the backing yarns are not bound together by the slight amount of polymer which migrates through to the backing and all the yarns are free to move relative to adjacent yarns.

The fabric has a full, fairly soft hand entirely suitable for automotive upholstery uses.

Example Il The procedure of Example I is repeated except that the fabric-pin frame assembly is completely immersed in the 4% Rhoplex HA-lZ emulsion until wet out completely. This fabric, containing the same amount of polymers, about 6%, is then drained and dried as before.

In the abrasion tests, the fabrics treated in this manner are inferior to the nylon fabric. In addition, the fabric band is harsh and boardy, making it unsatisfactory for upholstery uses.

Examination of the fabric under a microscope reveals that both the face and backing yarns are impregnated and bound together by the polymer.

Similarly, poor results are obtained when a 10% Rhoplex HA-l2 aqueous emulsion is padded onto the fabric, using a Butterworth padder having the single nip at 20 pound pressure and padding at a speed of approximately 20 feet per minute. Pick up in this instance is about 90%, corresponding to about 9% solids by weight on the fabric.

Abrasion results are quite poor compared to the nylon fabric and microscopic examination reveals that both the face and backing yarns are impregnated and bound together to provide an unsatisfactorily harsh and boardy hand to the fabric.

Example Ill Two quarts of a 35% aqueous dispersion of Rhoplex HA-12 is used to fill a hand-operated spray gun manufactured by the Binks Company. After adjusting the gun to spray at 7 pounds pressure, the fabric of Example I mounted on the pin frame is sprayed by moving the gun back and forth over the fabric from a distance of about 20 inches, three times in the warp-wise direction. The fabric (having about 10% solids by weight) and frame are placed in an oven at approximately 160 C. for 15 minutes.

The fabric so treated is equal or better than the nylon fabric in the abrasion tests, in that the treated fabric shows even less damage than the nylon fabric although neither fabric is damaged to a material extent. The hand of the treated fabric was satisfactory, though not as desirable as the fabric treated as in Example I.

Microscopic examination revealsV impregnation of the face yarns of the fabric, with fairly substantial, though less than 50% by number, bonding of those yarns. The backing yarns are neither impregnated nor bonded, the individual yarnsY and filaments being free to move relative to adjacent yarns and filaments. In the face yarns, slight movement of one yarn moves a plurality of adjacent yarns. This movement seems to balance the load on the fabric of abrasive forces, thereby contributing to the excellent abrasion resistance of the fabric. This fabric is highly desirable in most applications, but is slightly inferior in hand to the preferred fabrics.

Example IV A trough (9 inches inside length, 6% inches inside width, 71A. inches in height), having an opening at the bottom of about 1/2 inch is lined with a nylon fabric sold as Satin Type by Testfabrics, Inc., so that the fabric loops down through the opening to form a bag-like protuberance. A synthetic sponge about 1/2 inch wide is placed in the opening, separating the nylon bag and the trough, as a means of controlling the flow of Rhoplex IIA-12 from the trough to the nylon bag. In this manner, a one inch liquid level is maintained in the bag.

The trough is then filled to about one-half capacity with a 4% aqueous emulsion of Rhoplex HA-12 and the nylon bag fills to about a 1 inch level. No liquid leaks through the nylon bag.

The protruding nylon bag is dragged gently over the fabric-frame assembly of Example I, whereby an even coating of the Rhoplex HA-l2 is applied to the face yarns of the fabric. About 6% solids is picked up on the fabric in this manner. Since no draining is necessary in this procedure, the treated fabric is immediately placed in an oven at C. and fiash dried for 15 minutes.

In all the abrasion tests, the treated fabric performed equally as Well or better than the nylon fabric. In addition, the fabric is characterized by a very soft and full hand, providing ideal qualities for automotive upholstery applications.

Examination as before shows that only the uppermost filaments of the face yarns of the fabric are bound tightly together by the Rhoplex HA-12. Point bonding of the face yarns occurs at only a few locations, so that fabric identity is retained entirely.

This procedure is repeated on a continuous basis by passing the fabric at about 20 yards per minute in contact with the continuously filling nylon bag and into a tenter frame oven heated to about C. The heated air is directed upward from the backing through to the face of the fabric. Excellent results are also obtained in this manner.

Example V The fabric-frame assembly of Example I is placed on a cold glass plate of the same general dimensions prior to placement of the assembly in the oven. ThisV assembly is then introduced into the oven and flash dried as before.

The fabric so dried performs as well as the nylon fabric in the abrasion tests. Examination under the microscope illustrates results substantially equivalent to the excellent results obtained in Example IV. The hand of the fabric is similarly desirable.

Example VI The procedure of Example V is repeated except that a 5 50 by weight continuous filament viscose rayon, spun cellulose acetate fabric is substituted for the fabric of Example I. Equivalent abrasion resistance is obtained, although the hand of the fabric is not quite so good, though entirely suitable for upholstery uses.

We claim:

1. A flexible, porous, abrasion resistant fabric having a face composed of yarns composed of fibers, at least the uppermost of said fibers at the face being evenly coated and held tightly together by a polymeric composition, a

substantial proportion of said yarns being further characterized by an ability to move freely along their entire lengths relative to all adjacent yarns whereby the fabric remains porous flexible and more capable of resisting deterioration from abrasive forces.

2. The fabric of claim 1 wherein the face fibers consist essentially of synthetic polymeric continuous filaments.

3. The fabric of claim 1 wherein the face fibers consist essentially of viscose rayon filaments.

4. The fabric of claim 1 wherein substantially all the face yarns are characterized by an ability to move freely along their entire lengths relative to adjacent yarns.

5. The fabric of claim 1 wherein the synthetic polymeric composition holding the fibers tightly together constitutes from about 2 to about 15% by weight of the fabric.

6. A flexible, porous, abrasion resistant fabric having a face and a back composed substantially of continuous filament yarns, at least the uppermost filaments at said face being held tightly together by a synthetic polymeric composition, the filaments at said back being no more than loosely held together by a synthetic polymeric composition; a substantial number of said face yarns and substantially all of said backing yarns being free to move relative to adjacent yarns whereby the fabric remains porous fiexible and more capable of resting deterioration from abrasive forces.

7. The fabric of claim 6 wherein substantially all of the face yarns are free to move relative to adjacent yarns.

8. The fabric of claim 7 wherein the face yarns consist essentially of viscose rayon.

9. The fabric of claim 8 wherein the polymeric composition comprises an acrylic polymer.

10. A flexible, porous, abrasion resistant fabric composed of continuous filament and spun yarns, said fabric being woven such that the continuous filament yarns essentially form the face and backing of the fabric, at least the uppermost filaments of the continuous filament yarns forming the face of the fabric being evenly coated and held tightly together at the face by a synthetic polymeric composition adhered to the filament surfaces, the remaining filaments of said yarn being free to move relative to adjacent filaments; the filaments of the yarns forming the backing of the fabric being no more than loosely held together by a synthetic polymeric composition; a substantial number of said continuous filament yarns being further characterized by an ability to move freely along their entire lengths relative to all adjacent yarns whereby the fabric remains porous flexible and more capable of resisting deterioration from abrasive forces.

11. The fabric of claim 10 wherein substantially all of said continuous filaments are characterized by said ability to move freely relative to adjacent yarns.

12. The process of preparing a flexible, porous, abrasion resistant fabric having face yarns composed of fibers comprising applying at the face to at least the uppermost fibers of said yarns thereat, a polymeric composition in such a manner that a substantial number of said yarns forming said face remain free to move along their entire lengths relative to all adjacent yarns; and drying the polymeric composition at a rapid rate whereby at least the uppermost fibers of the yarns at the face of the fabric become tightly bound together, a substantial number of said yarns remaining free to move along their entire lengths relative to all adjacent yarns, to provide a ilexible, porous fabric more capable of resisting deterioration from abrasive forces.

13. The process of claim 12 wherein the fabric is dried by blowing air at the desired temperature through the fabric from the backing to the face of said fabric.

14. A flexible porous abrasion resistant fabric having a face and a back, said fabric being composed of continuous filament viscose rayon yarn and spun yarn, said fabric being woven such that the viscose rayon yarn essentially forms the face and backing of the fabric, at least the uppermost filaments of the viscose rayon yarns at the face of the fabric being evenly coated and held tightly together by `a synthetic polymeric composition adhered to the filament surfaces, the remaining filaments of said yarn being free to move relative to adjacent filaments; the filaments of the viscose rayon yarns forming the backing of the fabric being substantially free of said synthetic polymeric compositions; at least 50% of said viscose rayon yarns forming the face of said fabric being further characterized by an ability to move freely along their entire lengths relative to adjacent yarns whereby the fabric remains porous, flexible and more capable of resisting deterioration from abrasive forces.

15. The fabric of claim 14 wherein said polymeric composition has a heat distortion temperature after curing of at least about C., a cohesive force in excess of about 7 grams and a dynamic friction in film form below about 55 grams.

16. The process of claim 12 wherein the backing of the fabric is kept cooler during drying of the fabric, whereby the polymeric composition tends to migrate toward the uppermost fibers of the face yarns.

17. The process of claim 12 wherein polymeric composition is applied by contacting the uppermost fibers of the face yarns with a cloth container for the polymeric composition, said cloth being woven so that the polymeric composition will not flow therethrough except upon contact with said uppermost fibers.

References Cited in the file of this patent UNITED STATES PATENTS 2,619,705 Foster et al. Dec. 2, 1952 2,630,620 Rand Mar. 10, 1953 2,777,779 Harwood et al Jan. 15, 1957 2,810,948 Cogovan et al. Oct. 29, 1957 2,994,940 Ferrell et al. Aug. 8, 1961 3,023,482 Gilboy Mar. 6, 1962 

1. A FLEXIBLE, POROUS, ABRASION RESISTANT FABRIC HAVING A FACE COMPOSED OF YARNS COMPOSED OF FIBERS, AT LEAST THE UPPERMOST OF SAID FIBERS AT THE FACE BEING EVENLY COATED AND HELD TIGHTLY TOGETHER BY A POLYMERIC COMPOSITION, A SUBSTANTIAL PROPORTION OF SAID YARNS BEING FURTHER CHARACTERIZED BY AN ABILITY TO MOVE FREELY ALONG THEIR ENTIRE LENGTHS RELATIVE TO ALL ADJACENT YARNS WHEREBY THE FABRIC REMAINS POROUS FLEXIBLE AND MORE CAPABLE OF RESISTING DETERIORATION FROM ABRASIVE FORCES. 